Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D20/00—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00
  • F28D20/0056—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00 using solid heat storage material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
  • B23P11/00—Connecting or disconnecting metal parts or objects by metal-working techniques not otherwise provided for 
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B33/00—Clay-wares
  • C04B33/02—Preparing or treating the raw materials individually or as batches
  • C04B33/04—Clay; Kaolin
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
  • C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D15/00—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D17/00—Regenerative heat-exchange apparatus in which a stationary intermediate heat-transfer medium or body is contacted successively by each heat-exchange medium, e.g. using granular particles
  • F28D17/02—Regenerative heat-exchange apparatus in which a stationary intermediate heat-transfer medium or body is contacted successively by each heat-exchange medium, e.g. using granular particles using rigid bodies, e.g. of porous material
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
  • C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
  • C04B2235/602—Making the green bodies or pre-forms by moulding
  • C04B2235/6021—Extrusion moulding
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
  • C04B2235/94—Products characterised by their shape
  • C04B2235/945—Products containing grooves, cuts, recesses or protusions
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D20/00—Heat storage plants or apparatus in general; Regenerative heat-exchange apparatus not covered by groups F28D17/00 or F28D19/00
  • F28D2020/0065—Details, e.g. particular heat storage tanks, auxiliary members within tanks
  • F28D2020/0069—Distributing arrangements; Fluid deflecting means
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/14—Thermal energy storage
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49826—Assembling or joining

Definitions

• the present disclosure is generally directed to low void fraction thermal energy storage articles, systems, and methods for making and using such thermal energy storage articles and systems.
• Thermal energy storage technology exists that can recover, store, and withdraw heat energy, including natural energy such as solar thermal energy, terrestrial heat (e.g., volcanic, hydrothermal, etc.), and artificially produced heat energy such as industrially generated waste heat.
• Thermal energy storage systems can be broadly classified into sensible heat systems, latent heat systems, and bond energy systems.
• Sensible heat systems are those which store thermal energy by heating a medium, typically a liquid or a solid, without any change of phase.
• Latent heat systems are those which heat a medium that undergoes a phase change (usually melting).
• Bond energy storage systems are those which store thermal energy by having a medium undergo an endothermic-exothermic reaction that converts the thermal energy into chemical energy.
• Thermal energy storage improves performance of energy systems by smoothing supply and increasing reliability.
• solar energy is an abundant, clean, and safe source of energy, it suffers from yearly and diurnal cycles; thus necessarily being intermittent, and often is unpredictable and diffused due to variable weather conditions (e.g., rain, fog, dust, haze, cloudiness).
• variable weather conditions e.g., rain, fog, dust, haze, cloudiness
• the demand for energy is also unsteady; following yearly and diurnal cycles for both industrial and consumer needs. Therefore there continues to be a demand for improved, cost effective articles, processes, and systems that promote efficient storage, recovery, and usage of thermal energy.
• a thermal energy storage unit of the present invention generally includes a thermal energy storage body having a top surface, a bottom surface, a plurality of perforations that form passages extending through the thermal energy storage body from the top surface to the bottom surface.
• the thermal energy storage body of the thermal energy storage unit may also include an attached mixing cavity-creating element.
• the mixing cavity-creating element may be a separate unit used in conjunction with the thermal energy storage body when employed in a thermal energy storage system.
• the thermal energy storage body includes perforations, or openings, in the top and bottoms surfaces.
• the thermal energy storage body perforations also define passages, which may have shapes that are uniform, irregular, or any combination thereof, as they extend through the thermal energy storage body.
• the thermal energy storage body perforations also define an open face void as a percentage of the diameter of the perforations to the total face surface area.
• the thermal energy storage body perforations also define a void volume as the percent of the void of the passages with respect to the total area of the thermal energy storage body, wherein particular embodiments include a void volume range between about 1 0% to about 35%.
• An arrangement of two or more bodies and an intervening cavity defines a module, where the bodies are arranged adjacent together with a cavity in between the bodies, wherein the bodies are arranged such that the passages direct the flow of fluid through the bodies and the intervening cavity.
• the module includes a total void volume, wherein the sum of the void volume of the individual bodies and of the cavity is in a range of between about 1 0% and about 40%.
• the cavity is created by a cavity creating element, which may be a protrusion or a member that is integral with one or more surfaces of a thermal energy storage body, separate or external to the bodies, or extending from a containment vessel in which the bodies are disposed.
• a cavity creating element which may be a protrusion or a member that is integral with one or more surfaces of a thermal energy storage body, separate or external to the bodies, or extending from a containment vessel in which the bodies are disposed.
• thermal energy storage unit and module operation to control the flow of a fluid within the containment vessel.
• heat from the fluid may be transferred to the one or more thermal energy storage bodies in one operation and stored heat from the thermal energy storage bodies may be transferred to the fluid in another operation.
• FIG. 1 is an illustration of an embodiment of a thermal energy storage unit comprising a thermal energy storage body having an integral cavity-creating element (e.g., integral lip).
• an integral cavity-creating element e.g., integral lip
• FIG. 2 is an illustration of a thermal storage module comprising two thermal energy storage bodies and an external cavity-creating element (a spacer ring).
• FIG. 3A-3F are illustrations of cross-sections of alternate embodiments of thermal energy storage bodies having different shaped passages (e.g., circular, cross, straight slits, arcurate, S-shaped slits, and squares).
• shaped passages e.g., circular, cross, straight slits, arcurate, S-shaped slits, and squares.
• FIG. 4A-4C are illustrations of cross-sections of alternate embodiments of thermal energy storage bodies having passages arranged in different patterns (e.g., aligned multi-row array, non-aligned multi-row array, and radial).
• FIG. 5A-5C are illustrations of thermal energy storage bodies having alternate embodiments of integral cavity-creating elements (e.g., multiple protrusions, raised strips, single protrusion).
• FIG. 6A-6C are illustrations of a thermal energy storage unit having different integral cavity-creating elements on the top surface and bottom surface of the thermal energy storage body.
• FIG. 7A-7C are illustrations of a thermal energy storage bodies having alternate embodiments of external cavity-creating elements (e.g., multiple separable protrusions, multiple separable raised strips, single separable raised protrusion).
• external cavity-creating elements e.g., multiple separable protrusions, multiple separable raised strips, single separable raised protrusion.
• FIG. 8 is an illustration of a thermal energy storage unit having a thermal energy storage body comprised of multiple pie-shaped pieces arranged together.
• FIG. 9 is an illustration of alternate embodiment of a thermal energy storage unit comprised of concentric circular pieces.
• FIG. 10 is a flow diagram for a process of making a ceramic thermal energy storage body.
• thermal energy storage media that can be used in large scale thermal energy storage apparatus, such as those associated with solar powered energy generators.
• Particular inventive embodiments are directed to structured, modular, monolithic thermal energy storage media.
• the thermal energy storage media can be disposed within a container, such as a large pipe or containment vessel.
• a heat transfer fluid that has been charged (i.e., heated), such as by the sun, can be made to flow over and through the thermal energy storage media.
• the thermal energy storage media in turn absorbs heat from the heat transfer fluid and stores the absorbed thermal energy for later use.
• heat transfer fluid can be flowed through the heated thermal energy storage media so that the heat transfer fluid absorbs the stored heat and then transfers the heat to the generator where it can be used, for example, to generate steam.
• the thermal energy storage unit is comprised of a thermal energy storage body and a mixing cavity- creating element.
• the thermal energy storage module is comprised of at least two thermal energy storage bodies that are separated by a mixing cavity-creating element.
• the thermal energy storage system comprises a plurality of thermal energy storage modules.
• a thermal energy storage unit 1 00 comprises: a thermal energy storage body 1 01 having a top surface 1 03, a bottom surface 1 05, a plurality of perforations 1 07 that form passages 1 09 extending through the thermal energy storage body from the top surface 103 to the bottom surface 105, and a void volume in a range of about 10% to about 35%; and a mixing cavity-creating element 1 1 1 .
• the thermal storage properties of the thermal storage unit are influenced by the shape and dimensions of the thermal storage unit.
• the thermal energy storage unit has notable shape and dimensions of length, width, and height.
• the thermal energy storage body of the thermal energy unit can be any shape that has a top surface and a bottom surface and that has overall dimensions that allow it to fit within a containment vessel (not shown).
• the length and width of the thermal energy storage body are sized to be substantially equal to the interior length and width of the containment vessel.
• the thermal energy storage body can be smaller than the interior length and width of the containment vessel (such as for large containment vessels), such that multiple thermal energy storage bodies can be arranged side by side to fit within the containment vessel.
• the thermal energy storage body can be a unitary member.
• the thermal energy storage body can comprise a plurality of pieces that fit together to form the thermal energy storage body, wherein the plurality of pieces can comprise a single layer.
• FIG. 8 illustrates a thermal energy storage body formed from a single layer of a plurality of pie- shaped wedge pieces.
• FIG. 9 illustrates a thermal energy storage body formed from a plurality of concentric shaped pieces.
• the thermal energy storage body can have a length dimension in a range of not greater than about 60 inches (1 52.4 cm), such as a length not greater than about 48 inches (1 21 .92 cm), not greater than about 36 inches (91 .44 cm), not greater than about 24 inches (60.96 cm), not greater than about 20 inches (50.8 cm), not greater than about 1 8 inches (45.72 cm), not greater than about 1 2 inches (30.48 cm), not greater than about 10 inches (25.4 cm), not greater than about 8 inches (20.32 cm), or not greater than about 6 inches (15.24 cm).
• the length dimension can be not less than about 2 inches (5.08 cm), not less than about 3 inches (7.62 cm), not less than about 4 inches (1 0.1 6 cm), or not less than about 5 inches (1 2.7 cm).
• the length dimension can be within a range comprising any pair of the previous upper and lower limits.
• the length dimension can be in the range of not less than about 4 inches (1 0.1 6 cm) to not greater than about 1 2 inches (30.48 cm), such as not less than about 5 inches (1 2.7 cm) to not greater than about 1 0 inches (25.4 cm).
• the thermal energy storage body can have a width dimension in a range of not greater than about 60 inches (1 52.4 cm), such as a width not greater than about 48 inches (121 .92 cm), not greater than about 36 inches (91 .44 cm), not greater than about 24 inches (60.96 cm), not greater than about 20 inches (50.8 cm), not greater than about 1 8 inches (45.72 cm), not greater than about 1 2 inches (30.48 cm), not greater than about 1 0 inches (25.4 cm), not greater than about 8 inches (20.32 cm), or not greater than about 6 inches (1 5.24 cm).
• the width dimension can be not less than about 2 inches (5.08 cm), not less than about 3 inches (7.62 cm), not less than about 4 inches (1 0.1 6 cm), or not less than about 5 inches (12.7 cm).
• the width dimension can be within a range comprising any pair of the previous upper and lower limits.
• the width dimension can be in the range of not less than about 4 inches (1 0.1 6 cm) to not greater than about 1 2 inches (30.48 cm), such as not less than about 5 inches (1 2.7 cm) to not greater than about 1 0 inches (25.4 cm).
• the thermal energy storage body can have a height dimension in a range of not greater than about 60 inches (1 52.4 cm), such as a height not greater than about 48 inches (1 21 .92 cm), not greater than about 36 inches (91 .44 cm), not greater than about 24 inches (60.96 cm), not greater than about 20 inches (50.8 cm), not greater than about 1 8 inches (45.72 cm), not greater than about 1 2 inches (30.48 cm), not greater than about 10 inches (25.4 cm), not greater than about 8 inches (20.32 cm), or not greater than about 6 inches (15.24 cm).
• the height dimension can be not less than about 2 inches (5.08 cm), not less than about 3 inches (7.62 cm), not less than about 4 inches (1 0.1 6 cm), or not less than about 5 inches (1 2.7 cm).
• the height dimension can be within a range comprising any pair of the previous upper and lower limits.
• the height dimension can be in the range of not less than about 4 inches (1 0.1 6 cm) to not greater than about 1 2 inches (30.48 cm), such as not less than about 5 inches (1 2.7 cm) to not greater than about 1 0 inches (25.4 cm).
• the dimensions of length, width, and height are 6 inches (15.24 cm) by 6 inches (1 5.24 cm) by 1 2 inches (30.48 cm) (6" x 6 x 1 2") (1 5.24 cm x 1 5.24 cm x 30.48 cm).
• the void volume of the thermal energy storage unit can be influenced by the size, shape, and arrangement of the perforations (also called apertures, holes, openings, or voids) that are located on the top and bottom surfaces of the thermal energy storage body.
• the shape of the perforations can be regular or irregular.
• the shape of the perforations can be in the form of slits, regular polygons, irregular polygons, ellipsoids, circles, arcs, crosses, spirals, channels, or combinations thereof.
• the perforations have the shape of a circle.
• the shape of the perforation may be in the form of one or more slits, wherein multiple slits can intersect, such as in the form of a cross or star.
• the perforations are arcurate shaped.
• FIG. 3A-3F show examples of various shaped perforations.
• the concentration of the perforations on the top and bottom surfaces of the thermal energy storage body can be uniform or irregular.
• FIG. 4A shows a uniform concentration of perforations.
• FIG. 4C shows an irregular concentration of perforations.
• the top or bottom surface of a thermal energy storage body can have a concentration of perforations in a range of not greater than about 5 perforations per square inch (per 6.452 square cm), such as not greater than about 4 perforations per square inch (per 6.452 square cm), not greater than about 3 perforations per square inch (per 6.452 square cm), not greater than about 2.5 perforations per square inch (per 6.452 square cm), not greater than about 2.2 perforations per square inch (per 6.452 square cm), not greater than about 2.0 perforations per square inch (per 6.452 square cm), not greater than about 1 .9 perforations per square inch (per 6.452 square cm), not greater than about 1 .8 perforations per square inch (per 6.452 square cm), or not greater than about 1 .
• the top or bottom surface of a thermal energy storage body can have a concentration of perforations in a range of not less than about 0.25 perforations per square inch (per 6.452 square cm), such as not less than about 0.5 perforations per square inch (per 6.452 square cm), not less than about 0.8 perforations per square inch (per 6.452 square cm), or not less than about 1 .0 perforations per square inch (per 6.452 square cm).
• the concentration of perforations can be within a range comprising any pair of the previous upper and lower limits.
• the concentration of perforations can be in the range of not less than about 0.5 perforations per square inch (per 6.452 square cm) to not greater than about 3.0 perforations per square inch (per 6.452 square cm), such as not less than about 1 .0 perforation per square inch (per 6.452 square cm) to not greater than about 2.0 perforations per square inch (per 6.452 square cm).
• the perforations of the thermal energy storage body have a notable hydraulic diameter.
• the hydraulic diameter can be useful to characterize certain dimensional and structural features of the embodiments of the thermal energy storage unit, particularly with regard to the thermal energy storage body and the cavity-creating element.
• the hydraulic diameter of the individual perforations can be uniform or varying, the same or different.
• the average hydraulic diameter of the perforations can be in a range of not greater than about 2.0 inches (5.08 cm), such as not greater than about 1 .8 inches (4.572 cm), not greater than about 1 .6 inches (4.064 cm), not greater than about 1 .4 inches (3.556 cm), not greater than about 1 .2 inches (3.048 cm), or not greater than about 1 .0 inches (2.54 cm), not greater than about 0.9 inches (2.286 cm).
• the average hydraulic diameter of the perforations can be in a range of not less than about 0.1 inches (0.254 cm), such as not less than about 0.2 inches (0.508 cm), or not less than about 0.3 inches (0.762 cm).
• the hydraulic diameter can be within a range comprising any pair of the previous upper and lower limits.
• the hydraulic diameter can be in a range of not less than about 0.1 inches (0.254 cm) to not greater than about 2.0 inches (5.08 cm), such as not less than about 0.35 inches (0.889 cm) to not greater than about 1 .0 inches (2.54 cm).
• the spacing between adjacent perforations i.e., the wall thickness
• the wall thickness between the individual perforations can be uniform or varying, the same or different.
• the average ratio of hydraulic diameter to minimum wall thickness can be in a range of not greater than about 3.0, such as not greater than about 2.8, not greater than about 2.6, not greater than about 2.4, not greater than about 2.2, not greater than about 2.0, or not greater than about 1 .9.
• the average ratio of hydraulic diameter to minimum wall thickness can be in a range of not less than about 0.3, such as not less than about 0.4, or not less than about 0.5.
• the average ratio of hydraulic diameter to minimum wall thickness can be within a range comprising any pair of the previous upper and lower limits.
• the average ratio of hydraulic diameter to minimum wall thickness (D H /Thk) can be in a range of not less than about 0.5 to not greater than about 3.0.
• the perforations on the top or bottom surface of a thermal energy storage body can be arranged arbitrarily (e.g. randomly), or deliberately, in a myriad of patterns.
• the pattern of the perforations on the top surface can be the same or different as the pattern on the bottom surface.
• a pattern of perforations can be any pattern having a uniform distribution, a non-uniform distribution, or a controlled non-uniform distribution.
• a pattern of perforations can include: an array of vertical (as shown in FIG. 4A), diagonal (as shown in FIG. 4B), or horizontal rows and columns; a radial pattern (as shown in FIG.
• the pattern can cover (i.e., be distributed over) the entire top or bottom surface of the thermal energy storage body, can cover substantially the entire top or bottom surface of the thermal energy storage body (i.e. greater than 50% but less than 100%), can cover multiple portions of the top or bottom surface of the thermal energy storage body, or can cover only a portion of the top or bottom surface of the thermal energy storage body.
• the perforations on the top and bottom surfaces of the thermal energy storage body can define the shape of the passages that extend through the thermal energy storage body.
• the cross-sectional shape of the passages can be the same or different from each other.
• the cross-sectional shape of the passages can be uniform, irregular, varying, or any combination thereof, as the passage extends through the thermal energy storage body.
• the passages have a uniform cross-sectional shape that is the same as the shape of the perforation on the top surface to which the passage is connected.
• the cross-sectional shape of the passages changes as the passage extends through the thermal energy storage body.
• any particular passage connects at least one perforation on the top surface of the thermal energy storage body to at least one perforation on the bottom surface of the thermal energy storage body.
• the path of the passages can be non-torturous, tortuous, or combinations thereof.
• one or more of the passages is tortuous (i.e., irregular, that is, having a shape through the thermal energy storage body that includes curves and turns and is, therefore, not straight)
• one or more of the passages is non-tortuous (i.e., substantially straight) through the thermal energy storage body.
• the perforations define the open face area of the top surface or bottom surface of the thermal energy storage body.
• the passages define a void volume of the thermal energy storage body as the passages pass through the thermal energy storage body.
• the open face area of the top or bottom surface of the thermal energy storage body is in a range of not greater than about 38%, such as not greater than about 37%, not greater than about 36%, or not greater than about 35%.
• the open face area of the top or bottom surface of the thermal energy storage body can be in a range of not less than about 7%, such as not less than about 8%, not less than about 9%, or not less than about 1 0%.
• the open face area of the top or bottom surface of the thermal energy storage body can be can be within a range comprising any pair of the previous upper and lower limits. In a particular embodiment, the open face area of the top or bottom surface of the thermal energy storage body can be in a range of not less than about 10% to not greater than about 35%.
• the void volume of the thermal energy storage body can be in a range of not greater than about 38%, such as not greater than about 37%, not greater than about 36%, or not greater than about 35%. In an embodiment, the void volume of the thermal energy storage body can be in a range of not less than about 7%, such as not less than about 8%, not less than about 9%, or not less than about 1 0%. The void volume of the thermal energy storage body can be can be within a range comprising any pair of the previous upper and lower limits. In a particular embodiment, the void volume of the thermal energy storage body can be in a range of not less than about 1 0% to not greater than about 35%.
• the thermal energy storage unit includes a mixing cavity-creating element.
• the function of the mixing cavity-creating element is to create a mixing cavity, or continuous space, between two thermal energy storage bodies (i.e., a first thermal energy storage body and a second thermal energy storage body) that separates the opposing surfaces of the thermal energy storage bodies when they are placed adjacent to each other.
• Heat transfer fluid flowing through the various passages of the first thermal energy storage body is allowed to comingle, or mix, within the mixing cavity between adjacent bodies, which promotes temperature equalization and reduces the opportunity for any individual portion of the heat transfer fluid to have a temperature significantly above or below the average temperature of other portions of heat transfer fluid passing through the thermal energy storage body, thereby also reducing the opportunity for "hot-spots" to develop.
• the mixing cavity-creating element is integral to the thermal energy storage body. In another embodiment, the mixing cavity-creating element is external to the thermal energy storage body. In an embodiment, an external mixing cavity-creating element is component, such as a spacer ring, that is separate from the thermal energy storage body. In another embodiment, an external mixing cavity-creating element is a component that is part of, or extends from the containment vessel in which the thermal energy storage body is disposed.
• An integral mixing cavity-creating element can be integral to the top surface, the bottom surface, or both the top and bottom surfaces of the thermal energy storage body.
• an integral mixing cavity-creating element can be formed or molded on the top surface, the bottom surface, or both.
• an integral mixing cavity-creating element can be a protrusion that extends orthogonally from either or both of the top or bottom surfaces of the thermal energy storage body.
• the mixing cavity-creating element can be a plurality of integral protrusions that extend from either or both of the top or bottom surfaces of the thermal energy storage body.
• a protrusion can take any shape or form that does not obstruct the perforations on the surface of the thermal energy storage body.
• a protrusion can be regular or irregular.
• a protrusion can have a continuous or discontinuous shape.
• a protrusion can be located anywhere on the top or bottom surface of the thermal energy storage body.
• a protrusion can be a raised solid body, such as a polygonal prism, frusta, dome, or combinations thereof.
• a protrusion can be a strip, lip, wall, mound, or combinations thereof.
• At least one protrusion can take the form of a strip.
• a strip can be straight, curved, winding, angled, or combinations thereof.
• a strip can extend between adjacent perforations.
• a strip can surround one or more perforations.
• one or more strips can intersect.
• the protrusion is a lip that extends radially about the periphery of the top surface of the thermal energy storage body.
• FIG 1 shows an integral element, top surface, continuous lip or wall along periphery of the top surface of a thermal energy storage body.
• FIG 5(A) shows raised solid bodies at four corners of the top surface of a thermal energy storage body.
• FIG 5(B) shows two strips along the top surface of a thermal energy storage body.
• 5(C) shows a single raised square body in the middle of the top surface of a thermal energy storage body.
• FIG. 6A-6C show cavity creating elements on both the top and bottom surface of a thermal energy storage body.
• a protrusion from the top surface of one thermal energy storage body can be formed to interlock with, or complement in shape, a protrusion from the bottom surface of an overlying adjacent thermal energy storage body.
• a protrusion on the top surface of a thermal energy storage body can be in the shape of a semi-circle, while a protrusion on the bottom surface of an overlying adjacent thermal energy storage body can have a complimentary shaped semi-circle, such that when one body is placed above the adjacent body, the semi-circles interlock or complement a substantially complete circle.
• the height of a mixing cavity-creating element is notable and affects the size of a mixing cavity, or mixing cavities, created between adjacent thermal energy storage bodies.
• the height of a mixing cavity-creating element is related to the desired height of a mixing cavity, as well as the hydraulic diameter of the perforations on the top or bottom surface of the thermal energy storage body.
• the height of a singular protrusion, or the sum of multiple protrusions that are stacked upon each other can define the height of the mixing cavity between adjacent thermal energy storage bodies.
• the height of the mixing cavity is not greater than the average hydraulic diameter (D Ha vg) of the perforations on the top surface of the thermal energy storage body, such as not greater than about 0.9 D Ha vg, not greater than about 0.8 D Ha vg, not greater than about 0.7 D Ha vg, or not greater than about 0.6 D Havg -
• the total height of any mixing cavity-creating elements, singular or as a sum total is not less than about 0.1 D HaV g, such as not less than about 0.2 D HaV g, not less than 0.3 D HaV g, or not less than about 0.4 D HaV g-
• the total height of any mixing cavity- creating elements, singular or as a sum total can be within a range comprising any pair of the previous upper and lower limits.
• the total height of any mixing cavity-creating elements, singular or as a sum total can be in
• the mixing cavity-creating element can be a separable element (i.e., an external element) from the top surface of the thermal energy storage body.
• an external cavity-creating element can be an annular body, such as an annular ring (example shown in FIG. 7A-7C).
• An annular ring can be a circular ring, a square ring, a polygonal ring, or other shaped ring, such as a shape that matches the perimeter of the top surface of the thermal energy storage body (example shown in FIG 2.).
• the annular ring can be a spacer ring, spacer flange, spacer gasket, or the like.
• the external cavity-creating element can be a single annular body or a plurality of annular bodies disposed overlying each other.
• the mixing cavity has a height in a range of about 1 /3 to 1 times the average hydraulic diameter (D Ha vg) of the perforations on the top surface of the thermal energy storage body, therefore the total height of an external annular body, or the sum total of multiple annular bodies, will also be in a range of about 1 /3 to 1 times the average hydraulic diameter (D Ha vg) of the perforations on the top surface of the thermal energy storage body.
• an external mixing cavity-creating element can be a protrusion, a body, or a member, such as a support member, that extends from an interior surface of a containment vessel in which one or more of the thermal energy storage bodies are disposed.
• a containment vessel can include a support member, such as a shelf, upon which a thermal energy storage body can rest, the support member separating an upper thermal energy storage body from an adjacent lower thermal energy storage body by a distance that defines the mixing cavity between the thermal energy storage bodies.
• the support member can be a shelf made of angle iron.
• a thermal energy storage module comprises: a containment vessel; at least a first and second thermal energy storage body, each of the thermal energy storage bodies having a top surface, a bottom surface, a plurality of perforations that form passages that extend through from the top surface to the bottom surface, and a void volume of the thermal energy storage bodies in a range of about 10% to about 35%; a mixing cavity-creating element; and at least one continuous mixing cavity, wherein the first and second thermal energy storage body are disposed within the containment vessel and are positioned in series with the top surface of the first thermal energy storage body opposing the bottom surface of the second thermal energy storage body, wherein the mixing cavity-creating element is positioned between the top surface of the first thermal energy storage body and the bottom surface of the second thermal energy storage body, and wherein the at least one continuous mixing cavity is defined by the space between the top surface of the first thermal energy storage body and the bottom surface of the second thermal energy storage body.
• the thermal energy storage module has a notable void volume that affects the thermal energy heat storage properties of the module and includes the void volume of each of the abutting thermal energy storage bodies as well as the continuous mixing cavity that is present between the abutting thermal energy storage bodies.
• the total void volume for the thermal energy storage module can be not greater than about 40%, such as not greater than about 38%, not greater than about 34%, not greater than about 30%, not greater than about 28%, not greater than about 24%, or not greater than about 22%.
• the total void volume for the thermal energy storage module can be not less than about 8%, such as not less than about 9%, or not less than about 1 0%.
• the total void volume for the thermal energy storage module can be within a range comprising any pair of the previous upper and lower limits. In a particular embodiment, the total void volume for the thermal energy storage module can be in a range of about 1 0% to about 40%.
• the thermal energy storage bodies and mixing cavity-creating element that comprise the thermal energy storage module can be as described above in relation to a thermal energy storage unit.
• the perforations of the thermal energy storage bodies can be fully aligned with each other.
• the cavity-creating element deliberately separates the top surface of the first thermal energy storage body from the bottom surface of the second thermal energy storage body by a distance ranging from 1 /3 to 1 times the average hydraulic diameter of the perforations of the top surface of the first thermal energy storage body.
• the annular ring can be integral or separable from the thermal energy storage body.
• the cavity-creating element can be an integral or separable protrusion that extends from either the top surface of the first thermal energy storage body or the bottom surface of the second thermal energy storage body.
• the thermal energy storage module may further comprise a heat transfer fluid.
• the heat transfer fluids included will be determined based on the particular application and operating conditions of the heat collection and storage system under consideration.
• the heat transfer fluid will be an organic liquid, such as an oil.
• the oil can be a mineral oil, such as a mixture of paraffins and napthenes, high purity white mineral oil, mixtures of diphenyl-oxide and biphenyl, mixtures of diphenyl oxide and 1 ,1 - diphenylethane, a modified terphenyl, any combinations thereof, and the like.
• a mineral oil such as a mixture of paraffins and napthenes, high purity white mineral oil, mixtures of diphenyl-oxide and biphenyl, mixtures of diphenyl oxide and 1 ,1 - diphenylethane, a modified terphenyl, any combinations thereof, and the like.
• a thermal energy storage system comprises a plurality of the thermal energy storage modules that are disposed within one or more enclosures.
• thermal energy storage bodies, mixing cavity-creating elements, and containment vessels described herein can be manipulated so as to provide a method of controlling the flow of a heat transfer fluid within a containment vessel.
• a method of controlling the flow of a heat transfer fluid within a containment vessel comprises: directing the heat transfer fluid through a first thermal energy storage body that is disposed within the containment vessel and that has a cross-section matching the interior dimensions of the containment vessel; wherein the heat transfer fluid flows through a plurality of perforations that form passages that extend through the first thermal energy storage body from a front face of the first thermal energy storage body to a back face of the first thermal energy storage body; directing the heat transfer fluid to collect within a cavity having a volume defined by the cross-sectional area of the back face of the first thermal energy storage body and an orthogonal distance from the back face of the first thermal energy storage body to the front face of a second thermal energy storage body that is disposed within the containment vessel and is substantially similar to the first thermal energy storage body; and causing the heat transfer fluid to flow through the second thermal energy storage body, wherein the orthogonal distance is equal to an average hydraulic diameter of the perforations of the back surface of the first thermal energy storage
• FIG. 10 shows a particular embodiment of a method 1 000 of making a thermal energy storage unit.
• the process is initiated at activity 1 001 by mixing together ceramic components, including iron oxide, to form a ceramic mixture.
• the ceramic mixture is formed into a thermal energy storage body having an integral mixing cavity-creating element.
• the thermal energy storage body is heat treated to form a thermal storage unit.
• a thermal energy storage body can be formed from any material that provides sufficient structural strength, has sufficient thermal energy storage capacity, and that is compatible with an intended heat transfer fluid, as well as, any other chemicals, compounds, or other materials that will be in contact with the thermal energy storage body.
• the body can be formed from metal material, ceramic material, cermet material, vitreous material, polymer material, composite material, or combinations thereof.
• the metal material can be iron, cast iron, carbon steel, alloy steel, stainless steel, or combinations thereof.
• the thermal energy storage body can be a ceramic thermal energy storage body formed from ceramic materials.
• the ceramic material can be one of the group consisting of natural clays, synthetic clays, feldspars, zeolites, cordierites, aluminas, zirconia, silica, aluminosilicates, magnesia, iron oxide, titania, silicon carbide, cements, sillimanite, mullite, magnesite, chrome-magnesite, chrome ore, and mixtures thereof.
• the clays can be mixed oxides of alumina and silica and can include materials such as kaolin, ball clay, fire clay, china clay, and the like.
• the clays are high plasticity clays, such as ball clay and fire clay.
• the clay may have a methylene blue index, ("MBI"), of about 1 1 to 1 3 meq/100 gm.
• MBI methylene blue index
• feldspars is used herein to describe silicates of alumina with soda, potash, and lime.
• Other ceramic materials such as quartz, zircon sand, feldspathic clay, montmorillonite, nepheline syenite, and the like can also be present in minor amounts.
• the ceramic material can include oxides, carbides, nitrides, and mixtures thereof of the following compounds: manganese, silicon, nickel, chromium, molybdenum, cobalt, vanadium, tungsten, iron, aluminum, niobium, titanium, copper, and any combination thereof.
• External mixing cavity-creating components can be formed from the same materials described above used to form thermal energy storage bodies.
• a composition for forming a thermal energy storage body can comprise an iron oxide powder composition comprising the following major ingredients in the given concentration ranges:
• SiO 2 about 6 wt% to about 1 2 wt%
• AI 2 O 3 about 2 wt% to about 5 wt%
• MgO about 0 wt% to about 2 wt%
• concentration of the major ingredients can be adjusted and that as the amount of one component is increased, one or more other components can be decreased so that a 1 00% weight percent composition is maintained. Additionally it will be recognized that the above composition is for the major ingredients and that trace amounts of other compounds can be present.
• a composition for forming a thermal energy storage body can comprise a clay composition comprising the following major ingredients in the given concentration ranges:
• SiO 2 about 49 wt% to about 81 wt%
• AI2O3 about 22 wt% to about 38 wt% Fe 2 O 3 about 1 wt% to about 2 wt%
• MgO about 0 wt% to about 1 wt%
• a composition for forming a thermal energy storage body can comprise final composition comprising the following major ingredients in the given concentration ranges:
• SiO 2 about 19 wt% to about 31 wt%
• AI 2 O 3 about 6 wt% to about 10 wt%
• MgO about 1 wt% to about 1 .3 wt%
• TiO 2 about 0 wt% to about 1 wt%
• a ceramic mixture can be formed into a thermal energy storage body by any suitable method known in the art that is capable of shaping the ceramic mixture so that it has the proper dimensions, void volume, and if desired, an integral mixing cavity creating element. Extrusion, molding, casting, pressing, and embossing are all acceptable methods of forming a ceramic thermal energy storage body.
• External mixing cavity-creating components can be formed by the same methods described above used to form thermal energy storage bodies.
• the formed ceramic green body is heat treated, such as by calcining, sintering, or firing that alters the crystallite size, grain size, density, tensile strength, young's modulus, and the like of the ceramic material.
• heat treatment processes can generally be carried out in a temperature range, atmosphere, and pressure for a desired period of time that will depend upon the material composition of the green body.
• a composition comprising iron oxide, etc. can be fired at a temperature in a range of about 1 100 - 1 300 °C for a time period of about between 1 5 minutes to 1 2 hours.
• the Iron-Oxide powder, Clay powder, and soap can be mixed according to the manner below to make a composition suitable for forming: a thermal energy storage body, with or without an integral cavity-creating element, or an external cavity-creating element (e.g., spacer ring).
• the Iron-Oxide powder and Clay powder can be dry-mixed together for 4 minutes using an R-08 mixer. Seven (7) lbs. (3.1 8 kg) of de-ionized water can be mixed into the mixture for 3 minutes. Another five (5) lbs. (2.27 kg) of de-ionized water plus the soap can be mixed into the mixture for 3 minutes. Another three (3) lbs. (1 .36 kg) of de-ionized water can be mixed into the mixture for 3 minutes. Another two (2) lbs. (0.91 kg) of de-ionized water can be mixed into the mixture for 3 minutes.
• the mixture will then be ready for the extrusion and forming of the blocks and have a total moisture content of around 1 7%.
• they can be dried to less than 2% moisture and fired at 1 1 80 - 1 220 °C using a Tunnel kiln.
• they could be fired in another type of kiln, such as a gas, infrared, high-temperature, laboratory, periodic, pusher-type, roller hearth, or rotary kiln.
• composition of the final fired blocks will be as shown in Table 3.
• the height of the mixing cavity was calculated to be about 0.25 inches (0.635 cm).
• the average minimum wall thickness was calculated to be 0.45 inches (1 .14 cm).
• the height of the mixing cavity was calculated to be about 0.3 inches (0.762 cm).

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